Prefabricated structure for use in constructing outdoor fireplaces and the like and method of making same

ABSTRACT

A method for off-site manufacture of prefabricated monolithic fireplaces etc comprising a plurality of concrete blocks ; the method comprising the steps of constructing a first layer of blocks, providing a steel frame and securing the same to the blocks and to a second layer of blocks constructed atop the first layer, and constructing additional layers of blocks sequentially atop the second layer each block being adhesively secured to each of its adjacent blocks.

BACKGROUND OF THE INVENTION

Outdoor fireplaces, grill units, bars and even complete outdoor kitchens have been constructed on-site from concrete blocks and the like for some time and have been generally satisfactory. The cost of on-site construction, however, is substantial and quality control may be difficult to monitor and maintain in on-site construction resulting in a lack of structural integrity of the units and even in structural failure over time.

It is the general object of the present invention to provide a prefabricated monolithic structure of high structural integrity for use in the efficient construction of outdoor fireplaces and the like, and an off-site method of making the same.

It is a further object of the invention to provide a structure of the type mentioned which includes an integral high strength metallic frame resulting in a high degree of structural integrity of the overall structure, and which in turn facilitates the efficient transportation and on-site installation of the structure.

A still further object of the invention resides in the provision of lifting devices particularly well adapted to lift, transport and install the aforesaid structure.

SUMMARY OF THE INVENTION

In fulfillment of the aforesaid objects and in accordance with the present invention, an off-site prefabricated structure of concrete blocks or the like is provided with a first or base layer or course of blocks outlining the perimeter configuration of the structure. A rust proof frame of high strength metallic construction is provided with a configuration substantially the same as the base layer of blocks and is fixedly secured to the base layer of blocks in supporting relationship therewith to maintain their relative positions with respect to each other. A plurality of additional layers or courses of blocks are then provided atop the base layer of blocks and each block is affixed to each of its adjacent blocks by an adhesive bonding material.

In a presently preferred form, the blocks of the first layer are somewhat wider than those of the second layer to provide a narrow substantially horizontal inwardly extending shelf defined by the top surfaces of the first layer of blocks inwardly around the perimeter of the structure. The structural frame is generally L shaped in cross sectional configuration with one leg arranged horizontally and engaging and affixed to the top surface of the base layer of blocks and with an integral vertical leg engaging and affixed to the inner surfaces of the second layer of blocks. Preferably, the structural frame is both bolted to and secured adhesively to substantially all of the blocks in both the first and second layers of blocks.

While other high strength materials may be employed, the metallic frame is preferably constructed of structural strength steel with a rust proof coating. Various adhesives may also be used with a high strength masonry water-based bonding agent presently preferred.

In the preferred practice of the method of the present invention, conventional off-site facilities conducive to efficient quality control and efficient low cost production are provided. A first layer of blocks is provided in a desired perimeter configuration and adhesively affixed followed by a second narrow layer of blocks, which defines the shelf for receiving the frame. The frame is then affixed in secure engagement with both the first and second layers of blocks both adhesively and with suitable bolts.

Additional layers of blocks are then provided atop the second layer of blocks with each block in each layer throughout adhesively secured to each of its adjacent blocks.

On completion of one or more structures required for a particular outdoor unit, the structures are transported for on-site installation on large trucks and lifting devices of the present invention, to be described hereinbelow, may be employed for loading and unloading the trucks and for locating the structures in their desired on-site positions. A fireplace, for example may require two structures one atop the other. Other units may require two or more structures assembled in various side-by-side arrangements etc.

DESCRIPTION OF THE DRAWINGS

FIG. 1 of the drawings is a perspective view showing an outdoor fireplace comprising two (2) prefabricated structures of the present invention one atop the other,

FIG. 2 is a perspective view showing a fireplace similar to the FIG. 1 fireplace but with wood storage box units on each side thereof,

FIG. 3 is a grill unit including storage compartments and a sink and employing two (2) prefabricated structures of the invention in side-by-side relationship,

FIG. 4. is a bar unit comprising two (2) structures of the present invention in side-by-side relationship,

FIG. 5 is a perspective view of a lower fireplace with the front portion thereof broken away,

FIG. 6 is a plan view of a prefabricated structure of the present invention showing a metallic frame member forming a part thereof,

FIG. 7 is an enlarged fragmentary sectional view taken as indicated at 7,7 in FIG. 6 and showing a portion of the frame member,

FIG. 8 is a schematic side view of a prefabricated structure of the present invention being transported by a conventional forklift truck with the forks entered in parallel openings at the base of the structure,

FIG. 9 is a side view similar to FIG. 8 but showing the prefabricated structure lifted by an overhead lifting device with depending lifting members engaging the structure,

FIG. 10 is a schematic perspective view of the overhead lifting device,

FIG. 11 is a plan view of a prefabricated structure provided with lifting connections for an overhead lifting device, and

FIG. 12 is a fragmentary sectional view showing the overhead lifting device with a depending member connected with the frame of the structure.

DESCRIPTION OF THE PREFERRED EMBODIMENTS

Referring particularly to FIG. 1 of the drawings, an outdoor fireplace is indicated generally at 10 with a lower unit 12 and an upper unit 14, the lower unit 12 having a conventional front opening 16 and the upper unit 14 having a cap 18 and a vertical through opening internally and serving as a chimney for the lower unit which is open at the top. The fireplace is constructed of concrete blocks with exposed aesthetic surfaces and a decorative emblem 20 may be included on the face of the upper chimney unit 14.

In FIG. 2 the FIG. 1 fireplace is shown in association with left and right hand wood storage units 22, 22. The wood storage units 22, 22 are of similar construction with aesthetically pleasing concrete blocks and each is provided with a front opening 24 readily accessible for the storage of wood to be used in the fireplace.

FIG. 3 illustrates a somewhat larger unit 26 which may comprise similar units 28, 28 in side-by-side adjacent relationship with a unitary top 30 mounted on the units 28, 28. A sink may be provide as at 32, with an adjacent storage compartment 34 and a covered grill unit 36 with further storage units 38 accessible through the front wall of the unit.

FIG. 4 shows a bar unit indicated generally at 40 with storage compartments 42, 44 accessible in a top counter member 46 and front storage units accessible through doors 48 and 50. The unit 40 may conveniently be constructed of a pair of similar units 52, 52 disposed in side-by-side relationship with the counter 46 disposed atop both units.

In FIG. 5 a lower fireplace unit 12 a is shown with a portion of its front wall broken away at 54 to expose a portion of a metallic frame 56 better illustrated in FIGS. 6 and 7. The metallic frame 56 takes a rectangular configuration as best illustrated in FIG. 6 and is disposed atop a first layer or course of blocks 58, 58. In accordance with the method of the invention the blocks 58, 58 are arranged in the desired configuration for the perimeter of a structural unit in the course of the prefabrication of the unit. They may then be adhesively secured together with a pair of parallel openings 60, 60 in the front wall thereof and a similar pair of aligned openings 62,62 in the rear wall thereof. The openings 60, 60 and 62, 62 cooperate with a lifting device to be described more fully hereinbelow.

The frame 56 is of a high-strength rust-proof metallic construction such as structural steel and preferably takes an L shape configuration in cross-section as best illustrated in FIG. 7 with a horizontal portion 64 and an integral vertical portion 66. The horizontal portion 64 is secured to the shelf portions of blocks 58, 58 of the first layer or course of blocks preferably by an adhesive 68 and bolts 70, 70. Similar bolts 72, 72 secure the structural member 56 to the blocks 74 of a second layer or course of blocks disposed atop the blocks 58, 58 and somewhat narrower so as to provide the horizontal shelf for mounting the structural member 56 atop the blocks 58, 58. The vertical portion 66 of the structural member is secured to each of the blocks 74, 74 by bolts 72, 72 and by adhesive 68. Thus, the frame and the blocks of the first and second layers provide a base structure of high integrity for the structural unit 12 a. The metallic structural member 56 may also include a pair of U-shaped brackets 76, 76, one shown in FIG. 7, disposed in the aforementioned openings 60, 60. Similar brackets 76, 76 may also be provided in the openings 62, 62.

In accordance with the method of the invention, a plurality of blocks 78, 78 arranged in vertically stacked relationship may be assembled in a desired number of layers or courses atop the second layer of blocks 74, 74 with each block adhesively secured to all adjacent blocks to provide a monolithic structure of high structural integrity.

A first method of transport for the prefabricated structures involves the aforesaid openings 62, 62 and brackets 76, 76 and a conventional fork lift truck. As will be seen in FIG. 8, a fork lift truck 80 can readily be employed with its forks entered in the openings and brackets and in engagement with the structural metallic member 56 to lift, transport and deposit a prefabricated structural unit onto a truck for long distance transport and then from the truck to its final destination.

Secondly, and when the first method of transport is impractical or impossible to achieve, transport may be accomplished as illustrated in FIGS. 9, 10, 11 and 12. An overhead lifting device indicated generally at 82 can be provided for use with a fork lift truck 80. The device 82 comprises a main frame member 84 and at least one depending lifting element 86, four (4) preferred. The lifting elements cooperate with the structural frame 56 of a prefabricated structural unit and are manipulated by the frame member 82 and the fork lift truck 80 to lift and transport the prefabricated unit as necessary. As best illustrated in FIGS. 9, 11 and 12, the depending lifting elements 86,86 are connected at lower end portions with frame 56 as by threading the elements in the form of threaded rods into nuts 88,88 welded to the frame 56. At their upper end portions the rods 86,86 are lifted or lowered as required by the frame member 82 and the fork lift truck 80. Brackets 90,90 may be provided in two different right angularly related directions for this purpose.

Finally, it should be noted that the second method of transport has the advantage of ease in effecting a slight horizontal adjustment during final positioning of a structural unit. When the depending unit is held slightly above its final position by a fork lift, manual force can be applied laterally by attending workmen in a slight swinging movement for horizontally positioning within a matter of inches.

From the foregoing it will be apparent that a method has been provided for prefabricating a concrete block unit of high structural integrity at economic advantage. Highly effective methods of transport have also been provided. 

1. A method for the off-site manufacture of prefabricated monolithic structures comprising a plurality of blocks formed of concrete or the like and used in constructing outdoor fireplaces, grill and countertop units, bars and the like; the method comprising the steps of constructing a base layer of blocks in a desired configuration representing the perimeter of a structure, providing a rust proof structural frame of high strength metallic construction having a configuration substantially the same as that of the base layer of blocks, fixedly securing the frame in supporting relationship with interior surfaces of the base layer of blocks, sequentially constructing additional layers of blocks atop the first layer of blocks and atop each other, and affixing each of the blocks in each of the additional layers of blocks to each of its adjacent blocks by means of a high strength adhesive bonding material.
 2. A method as set forth in claim 1 wherein the structural frame is also fixedly secured in supporting relationship with interior surfaces of the blocks in a second layer of blocks.
 3. A method as set forth in claim 2 wherein the blocks of the first layer are somewhat wider than those of the second layer to provide a narrow substantially horizontal inwardly extending shelf defined by the top surfaces of the first layer of blocks around the perimeter of the structure, and wherein the structural frame is generally L shaped in cross sectional configuration with one leg arranged horizontally and engaging and affixed to the top surfaces of the base layer of blocks and with an integral vertical leg engaging and affixed to adjacent vertical interior surfaces of the second layer of blocks.
 4. A method as set forth in claim 3 wherein the structural frame is both bolted to and secured adhesively to substantially all of the blocks in both the first and second layers of blocks.
 5. A method as set forth in claim 1 wherein a high strength masonry adhesive is employed in bonding the blocks to each other.
 6. A method as set forth in claim 1 wherein an opening of substantial size is provided in a front sidewall of the structure so as to enable use of the same as a fireplace.
 7. A method as set forth in claim 6 wherein a second structure similar to the first and having a vertical through opening is fabricated and is placed atop the first structure to serve as a chimney.
 8. A method as set forth in claim 6 wherein a horizontal rust proof metallic header is provided and installed across the top of the fireplace opening with opposite end portions secured between vertically adjacent layers of blocks.
 9. A method as set forth in claim 1 wherein a substantially horizontal cooking grill of rust proof metallic construction is provided and mounted in a structure.
 10. A method as set forth in claim 9 wherein a second structure similar to the first is prefabricated and positioned adjacent and in close proximity to the first structure, and wherein a large unitary countertop is provided and positioned atop both the first and second structures, an opening being provided in the countertop member to receive the grill.
 11. A method as set forth in claim 1 wherein a second structure similar to the first is prefabricated and positioned adjacent and in close proximity to the first, wherein a large unitary countertop is provided and positioned atop both the first and second structures, and wherein a sink is provided in one portion of the countertop. 